Apparatus and process for melt spinning



Nov. 28, 196i G. T. DAvlEs ET AL APPARATUS AND PROCESS PoR NELT SPINNING 2 Sheets-Sheet l Filed Jan. 5l, 1958 ,e MMA, r m u Num MM/wr M026 q. w @mmf mi Gle 2ST@ mw MJm/o fila Mmm 7Mw/r fc5 5mm l G F.

B www@ W f M A ttorn e ys 2 Sheets-Sheet 2 Nov. 28, 96 G. T. DAVIES ET A1.

APPARATUS AND PROCESS FOR MELT SPINNING Filed Jn. 5l, 1958 United States Patent G 3,010,147 APPARATUS AND PROCESS FOR MELT SPNNING Gerald 'I'. Davies, Raglan, and Jeffrey ONeill Fisher, Dewi Madoc Jones, Geoffrey K. Lewis, and Eric Wilson, Croesyceiliog Cwmbran, and Thomas R. Grilin, Balby, Doncaster, and Eric J. R. Hewitt, Long Meadow, Stevenage, England, assignors to British Nylon Spinners Limited, Pont'ypool, England Filed Jan. 31, 1958, Ser. No. 712,499 Claims priority, application Great Britain Feb. 8, 1957 22 Claims. (Cl. 18-8) The Vpresent invention concerns improvements in or relating Itomen-spinning, and is particularly concerned with a process and apparatus for melt-spinning filaments, films, and 'the like from synthetic linear polymers such as nylon.

The art of melt-spinning (ie. the melting of solid filament-forming material followed by extrusion thereof in the mol-ten state) as developed over the past twenty years, has enabled the production of s-trong filaments and iilrns of very uniform character from those fiber-forming substances which decompose only at temperatures well above their melting-points. Thus, melt-spinning has been al widely-used method by which filaments have been spun from the synthetic linear polyamides and the synthetic linear polyesters.

Of recent years, there has arisen a demand for very strong filaments, such as the heavy denier yarns of nylon, for use as tire cords in the manufacture of motor tires. Tire cord is usually composed of plied multiiilament yarns having a total denier of about 840,

yarns can be made the longer the life and the safer will be the tires made with them. Thus a tenacity of at least.

9 grams per denier may be desired in nylon filamentsfor tire cord. For such a high tenacity, it is convenient to use, as raw material for the lilaments, a polymer having a higher relative viscosity than that normally required in the polymer from which textile filaments are spun. Thus, whereas the normal polymer is from 33 to 36, .that required for the'hgh tenacity tire cord is preferably of the order of 43. The relative viscosity of a polyamide is the ratio of the viscity of a solution thereof in ninety percent by weight formic acid containing ll grams of polyamide per 100 cc. of solution lat 25 C. to the viscosity of 90 percent formic acid yat the same temperature. It is with the difficulties inherent inthe melt-spinning of such relatively high viscosity polymers that this invention is chie-fly concerned, although the invention is useful for the meltspinning `of polymers of any relative viscosity suitable for the production of strong fibers, where high throughputs are required, as when spinning for tire cord o-r for tow.

The main diiiiculty inherent in melt-spinning high viscosity polymers in apparatus such as'that normally used and such as is described, for instance, in the specifications of British Letters Patent Nos. 533,307 and 653,757 is -that melting may not occur at a suiiicientrate for a truly productive process. This is due to the slowness with which the molten polymer comes away from the surfaces of the melting grid, due to its viscous'nature, when the only force acting upon it is that of gravity. A further diiculty arises from the propensity lof a high viscosity molten polyamide to form gel more quickly than one of normal viscosity if allowed to stand in the molten condition, and this propensity may be responsible for a further decrease in the rate of melting when a layer of gelled polymer forms on and adheres to the surfaces of the melting grid, as may well occur when there is no force other than gravity assisting in removing the molten polymer from the grid surfaces. Both these diflculties maybe overcome to a large extent by 'the use of pressure and the stronger thesev relative viscosity of nylon -sliglrtly in excess-of the spinning rate, and it follows that an excess pressure will be built up above the meltinggrid when molten polymer is unable to get away fast enough Vfrom the `grid surfaces. Means are therefore provided to allow the pressure-feeding means, which may be a screw within a cylindrical barrel, to retract from the grid once a certain pressure has built up and this move ment may be employed to actuate further means for stopping the feed or" solid polymer until the pressure has dropped -after the extrusion of a sufficient amount of the molten polymer. The apparatus is, therefore, self-balancing and relies on the pressure of the molten polymer above the melting grid to control the balance. With nylon polymer, at least, it is this very pressure, resulting in the dissolution of water deriving from the moisture contained in thesolid polymer, which creates the diiculty alluded to above, in that the variable pressure on the molten nylon having water dissolved therein leads to a varying amount of hydrolysis of the polymer to the extent that the relative viscosity of the polymer will vary and may drop from 4() to 20 at times. This quite clearly is a stater of affairs which renders the whole process nugatory. Certainly for nylon polymer, therefore, it is necessary to maintain the molten polymer at a constant pressure, preferably at or about atmospheric pressure,

. and this is preferably achieved, as described in the speci- ,r remove the lgaseous products of the slow decomposition of the molten polymer. In contradistinction to the apparatus described in the above-mentioned specification, however, it is not possible, when using means to supply the solid nylon polymer under pressure to the melting grid, to make use of the grid itself as the controlling means between the rate of melting and the rate of spinning owing -to the undesirable hydrolysis referred to above. We have therefore found it necessary to provide means that will m-aintain the level of the pool of molten lpolymer substantially const-ant, such means comprising a level sensing apparatus which is capable of controlling the pressure-feed means. Thus, as hereinafter described in more detail, -a desi-red arrangement for melt-spinning nylon polymer, provided in accordance with the present linvention, particularly high viscosity nylon polymer,

*stantially atmospheric pressure.

, of the same mel-ting area.

"polymer by the `feed means comprises a pressure feed means, a melting grid, a receptaolel for the accommodation of a pool of molten polymer below the grid, means'for removing molten polymer from the pool .and means for extrudi-ng it, and level sensing means to maintain the level of molten polymer in Ithe pool substantially constant at "a `given distance below the grid by control of the pressure feed means, the space abovey the surface of-the molten polymer being maintained under an atmosphere of water vapour at sub- With such an arrangement, the rate of melting 'may be increased to some 40 pounds per hour from the 5 pounds per hour or so which it is possible .to attainwith gravity melting apparatus The pressure exerted on the maybe of the order of 50 pounds per square inch, compared with a pressure of under 1 pound per square inch iu known gravity melting apparatus.

The amount of molten polymer that is to be accommodated in the receptacle will depend on the shape .thereof and on the rate 'of spinning, but must always be such that it ywill allouI a relatively'coarse control of the rate of feeding as it is obviously not desirable that there should ever be any risk of the amount of polymer availablev for spinning being below that required for the total denier required to be spun. In practice it has been found that a pool which allows of 7 minutes supply when lspinning nylon polymer of relative viscosity 43 at a speed of 19 pounds per'hour is suitable both from the point of view of the balance between 'rate of spinning and rate of melting, and rfrom the point of view of the prevention of thermal degradation of the molten polymer, which may occur if the polymer is allowed to remain in the molten condition for too great a time. v

The arrangement provided in accordance with the invention successfully overcomes the diiculties inherent in the known arrangements that are dependent on gravity. However, it is particularly desirable with high viscosity polymer to ensure that the polymer, as soon as it has been melted, is positively directed into the pool rather than allowed to `duip from the grid into the pool. ,When dripping of molten polymer has been going on from one place for any length of time, gel is likely to be formed at this spot and gradually a stalactite will take shape. Such stalactitites have a tendency to break olf after they have reached a certain size. In a melt-spinning apparatus they drop into rthe pool of molten polymer and subsequently may foul the extrusion pump or pumps, being particularly likely to bring about shearing of the pin inthe driving shaft of the so-called booster pump.V In the known gravity melting apparatus, the surface of the pool is normally at or above the level of the lower side of the melting grid, so that no dripping from the igrid into the pool takes place. But where, as in the present invention, the level of the surface of the pool is normally required to be below that of the bottom of the grid, dripping of polymer from Vthe grid will occur unless steps are taken to lead the molten polymer directly away from the (grid and positively direct its flow from the grid into the pool. Such means may be integral with the melting grid itself; that is to say, that the grid may for instance comprise melting surfaces and a base portion adapted to direct molten polymer into one or more channels leading directly into the pool, such that the surface of the pool is always, during opera-tion, maintained at or above the level of the delivery end Aof the channel or channels. Alternatively, the means may comprise a bafe plate, which may or may not itself be heated internally, fitted close beneath the under side of the fins or coils of theA melting grid and extending across the melting chamber, and provided with a drain or drains for directing polymer down a channel or channels into the pool in a similar way to that described above. In this manner, polymer is collected directly after beingmelted and is caused to llo-w in a continuous stream rather than drip into the pool. i

The present invention comprises, therefore, a process for melt-spinning tbreor nlm-forming material, wherein kmaterial in solid particulate form is forced under pressure to a heated melting means, the material is melted and the molten material is caused to flow in a continuous stream or streams downwardly into a pool of said molten material, above the surface of which is maintained an atmosphere substantially free of oxygen and substantially at a constant pressure at or about atmospheric pressure,

the level of the surface of the said pool automatically f being maintained substantially constant, and molten material is withdrawn from the said pool and spun into filaments, films or other shaped structures.

The invention also comprises apparatus for melting and spinning libreor film-forming material comprising means for forcing such material in solid particulate form under pressure to a melting means within a melting chamber, means for collecting molten material directly from said melting means and causing it to ilow in a continuous stream or streams downwardly :into a pool of said molten material maintained within that part of the chamber below said melting means, means lfor sensing the. level of the surface of said pool and for automatically maintaining the level substantially constant by a control of the feed means, means for introducing a gas 4for excluding free oxygen from that part o f the chamber between the said melting means and the surface of the said podl, and for keeping the pool at a constant pressure vat or `about atmospheric pressure, and means ifor withdrawing molten material from the said pool and for extruding it through a shaped orifice or orifices. Y

Convenient apparatus according to the invention will now be described with reference to the accompanying drawings and in connection with the melt-spinning of laments from nylon polymer of high viscosity. In the drawings,

`FIGURE l is a general view of one convenient apparatus above referred .toi y FIGURE 2 lis a sid-e view, partly in section of the screw feeding means of another said apparatus,

The apparatus as shown in lFIGURE l comprises, essentially,4 three interconnected sections, namely a feed section A, a melting section B, and an extrusion section C. The three sections will be described separately.

The feed section A as shown in FiGURE l comprises a `supply chute 1 for solid polymer in `chip o r ilake form, the said chute having an outlet 3-1 Within the lower part 21 of a chamber 23. This lower partY '21 is frusto-conical in shape `and narrows to the cylindrical bore 9 of a screw conveyor 3 comprising a double-start Z-flight screw 7, which is rotated by an electric motor (not shown) through gearing y15 and shaft 13. Immediately beneath the outlet of chute 1, a shelf 2 is secured to the 'conical side of the lower part 21 of theV chamber 2K3, and is spaced suiiiciently Afrom the said outlet to prevent chips or flakes of polymer from falling further into the chamber but to allow them to be moved lirstly in horizontal direction by radial spreaders 25 affixed to and rotating with the shaft 13. There are, infact, four such spreaders spaced at from each other, and theirfunction is to ensure controlled Yfeeding of polymer chips or akes to thev iirst flight of the screw, at a rate such that the screw is always ready to accommodate the fresh chips or lialrc's and such that no congestion of chips or iiakes'can occur above the screw, which might otherwise occur and lead to bridging of the chips or flakes and consequent starvation of the screw. Ports 33 are cut in the walls of chamber 23 above the frusto-conical lower part 21, and steam and other gases can escape easily to atmosphere therethrough. The outlet 31 has a cross-section that is small Vcompared with that of the chamber 21, and is such that the rate of descent of the polymer chips or flakes down the chute -1 is greater than the rate of ascent of the gases given olf by the melting chip or Hakes vn'thin the melting chamber 35. Consequently, there is no tendency for the steam or other gases to pass up the chute 1 .rather than through the ports 33, and there will therefore by no tendency for the chips andiiakes in the chute to coalesce leading to bridging An overload relay is fitted within the electrical supply circuit of the motor which is set to operate at a value of current corresponding to a state of affairs when the pressure in the upper part 77 of the melting 'chamber 35 has risen to a maximum permissible, safe amount say fo'f the order of 70 pounds per square inch. An unduefrise in pressure may occur, for instance, when, -for some reason such as a drop in the temperature of the melting surnot take lplace'fast enough compared with the controlled rate of feeding. The screw 7 delivers the chips or flakes to the upper part 77 of melting chamber 35, the walls of which part diverge so that the eventual width of the chamber above the heated melting grid 37 isabout double that of the barrel `9, as will be described in greater detail below in that part of the description relating to the melting section v i An alternative form of feed section yA is shown in greater detail in FIGUREv 2' and comprises a-supply chute 1 for solid polymer in chip or flake form, the said chute feedinginto the input end of a screw conveyor 3, the screw 7 of which is rotated by an electric motor 5,' through gearing 15 and rubbercoupling 17, at a speed to convey the solid material to the vmelting sectionB ata rate slightly in excess of the r'ate at which molten material is extruded from the apparatus. The screw conveyor which here, also, is shown mounted vertically comprises a two-ight screw 7 revolving within a short cylindrical barrel 9 leading into that part 77 of the melting chamber 35 above the meltingn grid. This part of the chamber widens out to labout double the width of the barrel, as Willbe described in greater detail hereinbelow. The shaft 13 of the screw conveyor 3 is re'siliently mounted by means of rubber coupling 17 for limited movement in the axial direction, such that if the pressure in the melting chamber above the grid rises above a certain amount, say, 70 pounds per square inch, the shaft will Withdraw in the direction away from the grid l and cause electrical contacts 19 to be opened to stop the drive to the screw.'. The configuration of the part 21 of the chamber 23 immediately above the screw 7 is frusto-conical, the cone half-angle being of the order of 45. The inside of the wall 23 of ,this part of the chamber is knurled. Mounted on the screw shaft 13 are two radially-extending spreaders 25, 27spaced by l20 from each other having their outer ends shaped to correspond with that of the knurled conical surface 29 of the chamber, and extending to within-a fractiorrof; an inc h, thereof. The angle -by, ;which the ,spreaders are separated from oneanother Icanfbe adjusted. The; outlet end31- of the -chute 1 supplying the polymer chip tothe Ascrew extends s omewhatinto the chamber 23 v and delivers `chip to` the chamber ata point close above the plane .of rotation of the spreaders'25,.. 27 and closeto the knurled wall 29 of the chamber. The cross-sectional area .of the outlet 31 issmall'comparedwith that ofthe chamber 21,. A plurality of ports 33 are cut inthe wall of thechamber at a level som'e inches above the chute outlet, to allow of ready venting of water vapor to atmosphere.

The particular means employed in feedingthe solid polymer chips to the input of t-he screw conveyor are o essential to prevent the formation of bridgesfof chipped polymer abovethe screw, which would otherwise be likely to occur owing partly to the occasional presence of ribbon-like chips amongstthe`more normal-shaped ones and partly to the water Vvapor given oifby the chipsof nylon polymer during` melting, Whichcondenses on the'chips in andabo've'the'screw'conveyor as the vaporrises, and causes thechips so affected` to adhere somewhat to one* another."

The crossls'ect'ional area of the outlet of the chute should( not, vofcourse, be so small"thatther e is'any danger ofthe solid particulate matter becoming'jammed across it, but it must be small enough to ensure that the downward rate of travel of the particulate matter at the outlet is greater than the upward rate of travel of any water vapor rising through the screw `,and the matter above it. This ensures thatnorwater vapor can get into the chute and lead to bridging of the particulate'rmatter therein. The spreaders shouldextend nearly to the Wall of the chamber above the screw and be mounted close above the first ilightlthereof. The outletro'f the'chute should be arrangedl tosupply th'eparticulate material close above the plane of rotationofthe spreaders andnear to thelwall of the said chamber.

These'means will ensure that only a thin layer of solid particulate matter ever lies above 4the screw, and this will not enhance the ease with which any long ribbon-like particles are accepted by the screw, but also will allow water vapor (or other vapor) an easy passage through it and thence to atmosphere through a suitable number of ports in the walls of the chamber above the outlet'from the chute. vThe spreaders will assist in the acceptance by the screw of the particulate matterin'a uniform manner, and the 'actual rate at which this matter is supplied to the screw can be varied (for any given cross-sectional area of outlet from thev chute) by a choice of the size, shape, number or position of the spreaders mounted on the shaft above the lirst flight of the screw. In this manner, the optimum feed rate to the screw may be established which, whilst maintaining a sufficient delivery of particulate matter to the melting means from the screw, will suiciently starve the screw ilight so as to make it more certain that all shapes of the particulate matter will be accepted by the screw and not help to form a bridge above the screw.

In order to achieve the most positive control by the spreaders on the particulate matter in the particular case of the apparatus illustrated in FIGURE 2, it has been found to be beneficial, as previously referredto, to have the inner surface of the wall of the chamber above the screw, which wall may be in the shape ofvan inverted frusto-cone, roughened, as by knurling.- yAt the same time,.it is best to have the screw'shaft highly polished, so that the maximum drag on'the particulate matter-occurs by its contact with the wallvra-ther than with the shaft.

The melting section B (see FIGURE l) comprises'the melting chamber 35 yand contains a heated melting grid 37, a baffle plate 39 with central drain 41, immediately below the grid, a pipe 43 leading down from the said drain into the lower part of the melting chamber, a gear pump 47 at the lower end of the said chamber driven by a shaft 49',- having a flexible portion v53, which enters the chamber through a gland 51 in one side of the chamber approximately level with the grid 37, an inlet pipe 55 for steam having its outlet above the lowerend 57 of the said drain pipe 43 and adapted to disperse steam through horizontally-directed orifices 59 to all parts of the melting chamber below the grid, an output channel 61 leading from the gear-purnp 47 to the extrusion section C, and a level sensing device 63, for controlling the level of molten polymer in a pool inthe lower portion 67 of the chamber. The melting grid may conveniently comprise seven hollow fins 69 of roughly triangular )shape in section through which is circulated a heating fluid, which is also circulated through ducts 71, 73 in the walls of the chamber at thelevel lof the grid. Owing to the pressureex-- erted on the polymer", forcing it down and throughV the grid, it is possible and desirable to have the lower parts of the fins much closer to one -another than in a gravity melter. The baille plate 39 extends right across the chamber ybelow thegrid and is separated by some 1/2 inch fromthe lower ends of the ins'of the gn'd. The central drain 4I in the baffle plate is of suitable size to allow vfor a free continuous flow of molten polymer through it and down the pipe 43 leading into the lower end of the 'chamber. The klei/'el sensing device'63 carries an electrode or probe 79 linserted into 'the chamber and connected to a circuit having a source of electric current. An electric current can be conducted by molten polymer, and the probe is arranged so that it will ybe suciently immersed in moltenvpolymer at a'certain level of the pool of polymer (say, 3 inches in depth) just above the lowerend of the drain pipe so that an electric-current passes round the circuit via the probe, the polymer andy the w-all 'of the melting chamber. The passage of this lcurrent can be rnade to control the motor of the 'screw conveyor, as will be described in greater detail hereinafter. The steam which is .injected into the chamber'through orices 59 below the grid is allowed to eeeape te atmosphere, with any other eases giver;y eff by the molten pelymer. through the gland 1 of the shaft of the gear pump. T he output of the gear pump is provided with a pressure relief orifice 75 allowing molten polymer to be returned to the pool in `the event, as is usuallythe case, of an excess of polymer being forwarded to the extrusion section.

In order to ensure eyen melting of polymer across the whole width of the melting grid 37, and in order to have a sufficiency o f solid material under pressure awaiting melting, it is arranged that there shall be a 'certain space '77 between .the end of the screw 7 (and its barrel 9) and Athe top of the melting grid 37. This space is laterally bounded by the walls of the melting chamber 35. Due to the friction between e.g nylon chip and the walls of the melting chamber, which are made, e.g. of mild steel, there would be a reaction in a direction opposite to the force applied by the screw if this space 'were cylindrical in shape, i.e. is a mere continuity of the barrel of the screw. Consequently, the walls of the chamber diverge from the end of the screw barrel and at an angle such that the half-angle of the trustecone s o formed is between l5o and 45. As illustrated the half-angle is 30 which is the preferred value.

As stated previously in general terms, the rotation of the screw conveyor 3 is effected by an electric motor 5, in the supply of which there is a starter circuit having a no-volts relay. Switches in the relay coil circuit can be controlled -by the pool level sensing means (i.e. probe 79'). Moreover iu the particular case of the apparatus described with reference to FIGURE 2 the switches are also controllable by the pressure-responsive means 4comprising the rubber coupling 17. If the pressure above the grid rises above a desired, and safe, v'amount the screw will be stopped either by the motor being tripped by an overload relay (FIGURE l), or by the pressure-responsive means including the rubber coupling acting on the novolts relay (FIGURE 2), and will not start again until, through lack of feeding, the pressure drops to the desired amount. If the level ofthe pool of molten polymer rises above that which is desired the screw will be stopped since the circuit including the probe will be rendered conductive `and the screw will not start again until, after extrusion of the requisite excess amount of molten polymer, the level drops to the desired position. In the vinstance of the aXially-displaceable shaft (FIGURE 2) the restoring force Lis provided by the rubber coupling between the screw shaft and a reduction gearing of 'the .screw motor. In this coupling, which may conveniently be a coupling sold under the trademark Metalstik Aa cylinder of rubber 83, bonded to inner and outer metal cy-y lindrical members 8S, 87, transmits the drive from the inner member 85 to the outer member 87, which latter is connected to the screw conveyor shaft 13. This rubber coupling, which can be pre-loaded in assembly, will allow limited axial movement of the screw conyeyor shaft dependent on the pressure in the solid particulate matter being vfed byethe screw. If the `rubber coupling is preloaded, v-the axial movement of the shaft will notoccur until a 'certain pressure is 'exceededY Once the motor lhas been stopped the pressure beneath the screw will drop as the solid matter vis melted. The stored energy in the rubber vcoupling will then force the screw downwards, and,

when the pressure has been lowered by the required amount, the contacts will be made again, and the screw motor started. In the probe control arrangements, the probe 79 projects downwards into that part 67 of the melting chamber 3S below the grid 37 and terminates atithe required height of the mclt-pool surface. A second probe can be inserted terminating just above this height. The change of electricalresistance between a probe `and ground when the vend of the probe is immersedin-the molten material, i.e. nylon polymer, is used to actuate a relay in an electrical circuit containing the probe, which in turn operates vthe rio-volts relay of the s'rew motor supply. In the case of a second probe which does not extend so` far downwards into the lower part ofthe chamber, it is arranged that it will actuate an alarm signal, as, of course, it will only ever come into action iu the event of the lower, Primary probe having failed. The necessary action can .then be taken to replaceor repair the defective primary probe 79.

For correct operation, it is essential that the probes shall always be well insulated from the wall ofthe melt-I iug chamber through which they extend.

. It has been found beneficial to insert a time delay' relay in the circuit controlled by the probe relay, in order that vthe screw motor Shall not be stopped by reason of any short-lived contact of molten polymer with the active probe, such as would arise from the possibly bubbly surface of the pool, before the true level of the surface had reached the height of the probe.

A suitable time delay circuit comprises a resistancecapacitance network incorporated in an electronic relay. Thus, when the potential at a point in the network falls due to conduction of electrical current through the probe and polymer, it is arranged that .the fall inY potential of the grid of a triode shall Ifollow after a suitable delay due to the resistance-capacitance network. When .the grid potential has by this means dropped slowly to a certain value, the triode changes from a fully conducting to a non-conducting state, and the relay is operated. The reverse applies when the probe becomes non-conducting after the level of polymer has once more dropped below it. That is to say, that after a suitable delay the triode suddenly changes into the fully-conducting state and deenergises the relay.

The extrusion section C comprises two gear-pumps 93, feeding molten polymer at a given constant rate to two spinneret assemblies of which one, 97, only is shown. These assemblies each comprise a iilter pack of sand 99 and a spinneret plate 101 having the desired number of small orifices through which the molten polymer is extruded .in the shape of laxnents. The sand is contained within holder 103, and is supported on a'sintered metal screen 105 itself supported on carrier plate 107 through which a number oforiiices serve to distribute `the molten polymer uniformly to all th e orifices of the spinueret. The spinneret assemblies may be separately heated although means so to do are not shown, vso as to enable the melt-spinning of the nylon polymerv to be assomplished at a given melting temperature and at a given same or different spinning temperature. l i l i In the operation of such melt-spinning apparatus, nylon polymer chip is supplied ycontinuously down supply chute 1 to the input of the vscrew conveyor 3 which forwards it to the melting grid 37 which is internally heated to 29.0 C. bythe circulation of a heated huid through the hollow members thereof. After the apparatus has been in operation a short time, the whole' part '77 'of the melting chamber above `the gridis filled with tightly-package polymer under pressure, the lower partsof which are forced down Vbetween the `@115,69 of the grid where the polymer is melted. The 'molten polymer is lpositively removed from the dns by' the pressure aboveit, andruns along the surface'of the baille plate 39to the drain 4 1 in the center thereof, and thence down the pipe yinto the pool. Molten polymer is withdrawn from the 'pool by the gear pump 47 at the :lower end of the pool ,'(th'esocalled booster pump) and forwarded along ducts to the extrusion section in the manner already known in the art. The volume of the connecting ducts is kept as small as possible in order to minimise the chances of vhydrolysis. The level sensing means maintain the level of the pool substantiallyY constant, the quantity of polymer in the pool being such that polymer passes through it in approximately 7 minutes when extruded at the rate .of 1'9 lpounds per hour. .The control of the level sensing means` on the screw conveyor shaft motor is such thatV the moto? is rutt-V 9 ning for, say, 3 minutes and switched oi for the next 3 minutes and so on.

The effect of the baffle plate, combined with the pressure feed and the thorough dispersion of steam below the grid, is to ensure that no-gel. is quickly yformed on any of the surfaces of the melting chamber above the surface of the melt-pool, and to ensure that the molten polymer is directed straight into the pool.

By the use of the -apparatus according to the invention, it is possible to melt-spin nylon yarns of a denier of 840 and a tenacity of over 9 grams per denier when drawn, at a rate of 19 pounds per hour; Whereas prior to the invention itv was impracticable to spin nylon yarns of this tenacity on a production basis at all. Furthermore, such apparatus is able to remain in operation, before having to be withdrawn for cleaning, something like ten times longer than any known gravity melting apparatus.

What we claim is:

1. Apparatus for melting and spinning a berand film-forming synthetic linear polymer material comprising melting grid means for melting said polymer material, feed means comprising a screw Hight for forcing said polymer material in solid particulate form under pressure to said melting means, chamber and conduit means for collecting molten polymer material directly from said melting means and for causing it to flow in a continuous stream downwardly into a pool of said molten polymer material, pool chamber means below said melting means for containing said pool, means for sensing the level of the surface of said pool and means operable in response to said sensing means for control of the feed means to automatically maintain the level substantially constant, means for introducing a gas for excluding free oxygen from. that part of the pool chamber above the surface of the said pool and for keeping the pool at a constant pressure of about atmospheric pressure, and means for withdrawing molten polymer material from the said pool and for extruding it through a shaped orifice or orifices.

2. Apparatus according to claim 1 in which the means for forcing the solid particulate polymer to the said melting means comprises a screw conveyor.

3. A process for melt-spinning a fiber and film-forming synthetic linear polymer, which comprises forcing said polymer in solid particulate form under pressure to a heated melting means, melting said polymer therein, owing the resulting molten polymer in a continuous stream downwardly into a separately maintained pool of said molten polymer, maintaining an atmosphere substantially free of oxygen and substantially at a constant pressure of about atmospheric pressure above the surface of said pool, controlling the rate at which said solid particulate polymer is forced to said melting means in accordance with the level of the surface of said pool to maintain said level substantially constant, withdrawing said molten polymer from the said pool and feeding the same to spinning means, and spinning the same into shaped structures.

4. A process for melt-spinning a fiber and nlm-forming synthetic linear polyamide, which comprises forcing said polyamide in solid particulate form under pressure to a heated melting means, melting said polyamide therein, owing the resulting molten polyamide in a continuous stream downwardly into a separately maintained pool of said molten polyamide, maintaining an atmosphere substantially free of oxygen and substantially at a constant pressure of about atmospheric pressure above the surface of said pool, controlling the rate at which said solid particulate polyamide is forced to said melting means in accordance with the level of the surface of said pool to maintain said level substantially constant, withdrawing said molten polyamide from the said pool and feeding the same to spinning means, and spinning the same into shaped structures.

5. A process according to claim 4 in which the synthetic linear polyamide is a polyamide of a relative viscosity greater than 36. v

6. A process according to claim 5 in which the pool of molten polyamide is maintained at substantially atmospheric pressure by injecting steam into the melting chamber above the surface of the said pool, and allowing Said steam to escape to atmosphere.

7. A process according to claim 6 yin which the level of the surface of the said pool is maintained substantially constant by intermittently over-feeding the solid polyamide material and jointly controlling the ratev of feeding with the said level of the surface of the said pool.

8. A process according to claim 7 in which the said controlling of the rate of feeding as further defined as electrically controlling the rate of feeding by passing a current of electricity through said pool.

9. A process according to 'claim 7 including, during a period of over-feeding, holding the rate at which solid polyamide material is removed from a mass thereof at a substantially constant rate correlated with the rate at which saidmaterial is forced under pressure to the heated melting means. f -l 10. A process according to claim 5 inwhich the pressure at which the solid polyamide material is forced is of the order of 50 pounds per square inch.

1l. Apparatus according to claim 2 in which the said melting means comprises a grid heated internally by a fluid circulated therethrough.

12. Apparatus according to claim 11 in which the walls of that part of the melting chamber between the output end of the said screw conveyor and the top of the said grid diverge at an angle such that the half- `angle of the frusto-cone so formed is between 15 and 45.

13. Apparatus according to kclaim 1l in which the means for collecting molten polymer material directly from said melting means comprises baille plate means extending across the said melting chamber and closely spaced below said grid, said plate having a central drain, `conduit means connected to said central drain and extending downwardly into said pool of molten polymer material which is conned within the lower part of the said chamber.

14. Apparatus according to claim 11 in which the means for sensing the level of said pool comprise at least one probe extending into the lower part of the said chamber to an extent such that the lower end thereof is at the desired level of the said pool, the said probe being electrically insulated from the wall of the said chamber through which it extends and being incorporated in an electrical circuit associated with the motor driving the said screw conveyor.

15. Apparatus according to claim 14 in which the electrical circuit comprises a resistance-capacitance network incorporated in an electronic relay capable of actuating a second relay in the supply circuit of an electric motor for driving said screw conveyor.

16. Apparatus according to claim 2 and having means for supplying said solid particulate polymer material to said screw conveyor at a rate correlated with the rate of fonwarding of the said polymer material by said screw conveyor.

17. Apparatus according to claim 16 in which said means for supplying said solid particulate polymer material comprise spreaders attached ot and extending radially from the shaft of said screw conveyor and adapted to spread the said material emanating from a chute filled therewith laterally above the input end of the said screw conveyor.

18. Apparatus according to claim 17 in which the outlet end of the said chute extends into a chamber above the input end of the said screw conveyor, the said outlet having a cross-section which is small in cornparison with that of the said chamber, and in which the said outlet terminates at a heightjust above the plane of rotation of said spreaders, and a shelf formed 11 within the said chamber and positioned beneath` said outlet and juxtaposed below the plane of rotation of said spreaders.

19. Apparatus according to claim 2 and having means for intermittently Stopping said screw conyeyor and ac,- tuated when the pressure" exerted thereby weeds a cerf tain predetermined amQl-Uli.

2Q. Apparatus according to Claim 19 inwhicph `said means .for internttently Stopping Said Screw Conveyor comprises, an over-load relay in lthe supigily circuit of 4an electric motor .for driving said screw eonveyor.

2l, Apparatus according to claim 19 in Awhich said means for intermittently stopping said screw conveyor comprises a pre-loaded rubber coupling in the driving shaft of said screvyl conveyor, and electrical v contacts aadpted to be made or broken when lthe said screw conveyor is moved axially away from said melting means by a certain amount corresponding to said certain pre: determined pressure, and an electrical circuit including said contacts and a relay in the supply circuit of an electric .motor for driving said Screw CQnYei/@- 22. A process -for melt-spinning a ber and lmV-forming synthetic linear polyamide, which comprises foroing Said polymer in Solid partiwlate form under pressure to a heated melting means, melting said polyamide therein, ilowing the resulting molten polyamide in a conrate at which v"said solid, particulate polyamide is forcedy to'said melting means in accordance with the level of the surface of said/perrito maintain its level substantially constant, withdrawing saidmolten'polyamide from the said pool and lfeedingthe same' to spinning means, and spinning the same intoshapedstructures.` A

f References Cited in the tile of this patent Uma@ STATES PATENTS' 2,253,176 Graves Aug. 19, 1941 2,369,553 Freins V per. 13 1945 2,437,686 Dreyfus' Mar. 16, 1948 2,571,975 Waltz Oct. 16, 19,51 2,719,776 Kummtel Oct. 4v, 19A-55 2,791,802 Weber May 14, 19,51 ,2189121628 Phipps Aue 11 195,9. FORBtQN PATENTS 744,855 Great Britain IFeb. 15, 195.6l 551,431 Italy' Nev, '20, 195g 

